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<p>This study investigates the effect of selective laser melting (SLM)-based additive manufacturing (AM) process parameters on the solidification dynamics and microstructure evolution in IN718 using volume energy density (VED). A broad processing window was explored, with scan power varied from 120 to 400 W, scan speed from 300 to 1400&#xa0;mm/s, hatch distance from 0.0463 to 0.1544&#xa0;mm, and VED from 36.86 to 303.03&#xa0;J/mm<sup>3</sup> enabling comprehensive microstructural and defect analysis. Three distinct sample sets were designed to systematically investigate the effects of scan power and scan speed over a wide VED input range (Set I), scan power and scan speed varied at constant VED (Set II), and scan power and hatch distance varied at constant VED (Set III). The correlation between VED, grain size, cell spacing, defect formation, and porosity has been established and experimentally validated using optical and scanning electron microscope. The findings provide valuable insights into the optimizing process parameters, minimize defects, and tailor microstructural features of additively manufactured components. The examination of samples with constant VED revealed that scan power has a more significant influence compared to scan speed and hatch distance. The analysis indicates that the parameter combination of 280 W scan power, 960&#xa0;mm/s scan speed, and 0.1100&#xa0;mm hatch distance (VED = 66.29&#xa0;J/mm<sup>3</sup>) results in samples with reduced defect density, finer PDAS, lower porosity, and minimized grain size anisotropy. Defect formation mechanisms were investigated and corroborated using optical and SEM micrographs, complemented by quantitative area porosity percentage analysis. The proposed analytical formulation, derived from the experimental results, describes the observed relationship between SLM process parameters and microstructural characteristics, within the studied ranges of process parameters.</p>

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Effect of laser powder bed fusion parameters on solidification, microstructure evolution and defects in IN718: experimental investigations and analytical formulations

  • 期刊论文

  • 发表日期：

    2026年3月27日

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  • M. N. Nazeemudheen,
  • Sushant Manwatkar,
  • S. V. S. Narayana Murty,
  • Srinu Gangolu

摘要

This study investigates the effect of selective laser melting (SLM)-based additive manufacturing (AM) process parameters on the solidification dynamics and microstructure evolution in IN718 using volume energy density (VED). A broad processing window was explored, with scan power varied from 120 to 400 W, scan speed from 300 to 1400 mm/s, hatch distance from 0.0463 to 0.1544 mm, and VED from 36.86 to 303.03 J/mm3 enabling comprehensive microstructural and defect analysis. Three distinct sample sets were designed to systematically investigate the effects of scan power and scan speed over a wide VED input range (Set I), scan power and scan speed varied at constant VED (Set II), and scan power and hatch distance varied at constant VED (Set III). The correlation between VED, grain size, cell spacing, defect formation, and porosity has been established and experimentally validated using optical and scanning electron microscope. The findings provide valuable insights into the optimizing process parameters, minimize defects, and tailor microstructural features of additively manufactured components. The examination of samples with constant VED revealed that scan power has a more significant influence compared to scan speed and hatch distance. The analysis indicates that the parameter combination of 280 W scan power, 960 mm/s scan speed, and 0.1100 mm hatch distance (VED = 66.29 J/mm3) results in samples with reduced defect density, finer PDAS, lower porosity, and minimized grain size anisotropy. Defect formation mechanisms were investigated and corroborated using optical and SEM micrographs, complemented by quantitative area porosity percentage analysis. The proposed analytical formulation, derived from the experimental results, describes the observed relationship between SLM process parameters and microstructural characteristics, within the studied ranges of process parameters.